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CONTENT
1. Description ............................................................................................ 2
1.1 Objective .................................................................................................. 2
2. Demo Instructions................................................................................. 2
2.1 Study Overview ......................................................................................... 2
2.2 System Parameters ................................................................................... 3
2.3 Find the Optimum number of Pallets (*) ....................................................... 5
2.4 Find the Bottleneck ................................................................................... 8
2.5 Test New Layout ....................................................................................... 9
3. Worker Utilization ............................................................................... 10
4. Conclusion ........................................................................................... 10
1. Description
This model shows a production and assembly system with a pallet-based transport system. The system
contains manual and automatic Workstations. One part per pallet runs through the system and is
processed on the stations according to the process times.
Each station has cycle times, certain availability and the manual stations need a worker to start. These
parameters determine the time a part stays on the station.
Note, that some actions in this description are not available in the Plant Simulation Viewer (in case you run
this model from the Plant Simulation Demo-CD), since the Plant Simulation Viewer does not allow any
modeling or changes of parameters. Actions which are not allowed in the Plant Simulation Viewer are
marked with an asterix (*). In the model for the Plant Simulation Viewer, some of the actions marked with
an asterix (*) will happen automatically at the end of the simulation.
1.1 Objective
The objective is to optimize the number of workers, pallets and the capacity of buffers to maximize the
throughput. Therefore, this model shows how to solve two typical problems every simulation engineer has:
1. In a real production system, there are always several values to optimize (e.g. maximize throughput
rate and minimize throughput time) and several parameters you can change (capacities, logic,
layout). In most cases, some parameters affect other parameters, too (e.g., if you decide to
decrease the capacity of buffers, the optimum number of pallets might decrease, too). This results
in the problem, that a user should run experiments for all possible combinations of values for
those parameters to find the optimal result result. Normally, this is not possible. The
ExperimentManager in Plant Simulation can solve this problem by executing a certain number of
simulation runs by itself and by using neural networks to calculate the optimum combination of
parameters from the results.
2. Some values in a real system have a random behavior, e.g. the point in time when a machine
breaks down or the cycle time of manual operations. In this case, its not sufficient to run just one
simulation experiment, because the results of this simulation experiment are based on the random
numbers from this experiment. When you run the same experiment with different random
numbers, you will get different results. So how can you base a decision over a multi-million dollar
system on simulation experiments? The solution is, to run multiple experiments with different
random numbers and to calculate a confidence interval from the results. The ExperimentManager
in Plant Simulation can tell you that e.g. with a probability of 99 % (which is the confidence
level), the mean throughput of your system will be in the range of 45.2 to 45.5 units per hour.
2. Demo Instructions
2.1 Study Overview
Start a simulation run in the frame Assembly1 using the button Start in the model.
shows the parameter we would like to change to optimize the result. In both tables you can provide
understandable descriptions that are used in the evaluation of the experiments.
A click on Define Experiments opens a table which shows in which values we would like to set. On the tab
Definition, you find the number of simulation runs with different random numbers (Observations).
Look at the page Overview of the report. It shows the input and output values for each experiment. On
the page Output values of interest, you see a chart which shows the confidence interval for each step. It
shows for each experiment the range in which the mean value of the throughput will be with a 90 %
probability.
Working (green)
Waiting (grey)
Blocked (yellow)
Failed (red)
Stopped (rose)
From the chart you can see, that the stations MS3, MS4 as well as AS2 and AS3 show a certain blocking
percentage (yellow). On the other hand side, you see that most stations show a waiting percentage (grey).
This indicates that there is a bottleneck at stations AS3/AS4 and MS4.
Right-click the Buffer Usage histogram shows the percentage of time a certain quantity of parts was located
on a conveyor.
Double-click the Quantity object in the Assembly2 frame and set the value to 29. Click on the Reset button
and on the Start button in the toolbar of Assembly2. Open the utilization chart for the stations and
compare the result.
3. Worker Utilization
To look at the utilization of the workers, right-click the Worker-Utilization object and choose View Chart
from the context menu.
Working (green)
Waiting (grey)
The chart tells you that the workers at the manual workstations have a high utilization. The utilization of
the Adjusters is very low.
4. Conclusion
Even a system that looks so simple shows a complex behavior, due to stochastical parameters.
Even if two stations have the same mean value of the cycle time, the second station can be a bottleneck, if
the two stations use a different random numbers distribution.
Summary: Plant Simulation provides all the tools you need to base your decisions on reliable
results. Plant Simulation provides multiple easy-to-use tools to evaluate your system. These tools
allow you to identify bottlenecks and find resources which are not well utilized.
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